In-line method of manufacture of ostomy appliance faceplate

Abstract

A low-profile faceplate assembly for a two-piece ostomy appliance, and a method for manufacturing it, are disclosed. The faceplate includes a wafer of an adhesive skin barrier material and a flexible plastic coupling ring (for detachably coupling the faceplate to an ostomy pouch having a mating ring), and is distinguished by the mounting flange of the coupling ring being embedded within the faceplate. The faceplate is made by a convergence of in-line processes taking place simultaneously with an injection/compression molding operation for the skin barrier wafer as disclosed in U.S. Pat. No. 5,716,475, thereby eliminating or greatly reducing the assembly labor for the various process steps plus the handling, storing and transferring steps commonly associated with the manufacture of ostomy faceplate assemblies.

What is claimed: 
     
       1. An in-line method of making adhesive faceplates for two-piece ostomy appliances comprising the steps of intermittently advancing flexible first and second webs through an injection/compression molding station in which discrete mounds of soft, adhesive skin barrier material are deposited on one of said webs and are then successively compressed between said webs to form a series of wafers of skin barrier material of selected size and shape; simultaneously affixing a series of thermoplastic coupling rings with annular attachment flanges to one side of a flexible third web, with said coupling rings being affixed to said third web by said attachment flanges, and advancing said third web with said coupling rings carried thereby, and said first and second webs with said wafers therebetween, to a delaminating/laminating station; stripping said first web and replacing the same with said third web in synchronized relation at said delaminating/laminating station with each of said coupling rings being directly aligned with each of said wafers; providing a cover-applying station and laminating at said cover-applying station a fourth web of flexible covering material to both said third web and said flanges of said coupling rings; said fourth web having a series of uniformly-spaced openings therein with each opening being sized and located to register with one of said coupling rings at said cover-applying station to expose a portion of each coupling ring therethrough while at the same time covering the annular attachment flanges thereof, thereby sealing said attachment flanges of said series of coupling rings between said third and fourth webs; and thereafter advancing said second, third and fourth webs with said wafers and coupling rings carried thereby to a cutting station where said second, third and fourth webs are cut at or just within the periphery of each wafer, thereby detaching a succession of discrete adhesive faceplates from said webs. 
     
     
       2. The method of claim 1 in which said step of laminating said fourth web of flexible covering material to both said third web and said coupling rings at said cover-applying station occurs beyond said delaminating/laminating station. 
     
     
       3. The method of claim 1 in which said step of laminating a fourth web of flexible covering material to both said third web and said coupling rings at said cover-applying station occurs in advance of said delaminating/laminating station. 
     
     
       4. The method of claim 1 in which said fourth web is adhesive-coated on one side and said adhesive coating is brought into contact with said third web and said flanges of said coupling rings at said cover-applying station. 
     
     
       5. The method of claim or 2 in which a flexible but substantially non-stretchable backing covers the adhesive coating of said fourth web and is stripped from said fourth web to expose said adhesive coating to said flanges and said third web at said cover-applying station. 
     
     
       6. The method of claim 1 in which said fourth web is formed of fabric. 
     
     
       7. The method of claim 6 in which said fabric of said fourth web is nonwoven. 
     
     
       8. The method of claim 1 in which there is the further step of cutting said second and third webs and said wafers at said cutting station to form an opening therethrough located at the center of each coupling ring. 
     
     
       9. The method of claim 1 in which there is the further step of contouring each of said wafers at said injection/compression molding station, with each wafer being contoured to provide a thin peripheral portion and a thicker central body portion. 
     
     
       10. The method of claim 1 in which said third web is formed of heat-sealable thermoplastic material and said step of affixing said coupling rings to said third web occurs by heat sealing said flanges of said coupling rings to said third web in advance of said delaminating/laminating station. 
     
     
       11. The method of claim 10 in which said third web has a flexible but substantially non-stretchable backing laminated thereto; said backing being stripped from said third web before said third web is laminated to said wafers and said second web at said delaminating/laminating station. 
     
     
       12. The method of claim 10, in which said third web is adhesive-coated and the adhesive coating thereof is brought into contact with said wafers and said second web at said delaminating/laminating station.